No-Sew DIY Tiller Pilot Cover

Water kills more tiller pilots than wear and tear. This 10-minute DIY cover uses basic materials you probably have on hand to shield your autopilot from rain and spray without cooking the electronics.

By
Drew Frye
-
2
This no-sew tiller pilot cover is made from a recycled dodger window. (Photo/ Drew Frye)
This no-sew tiller pilot cover is made from a recycled dodger window. (Photo/ Drew Frye)

Although they are rated waterproof, the most common cause of death for tiller pilots is water intrusion. I've had one die from this. Like most electronics, they pull a vacuum inside when a summer thunderstorm hits them and lowers the temperature of the enclosure from as high as 130 F to just 70 F in a few minutes. They leak either through the case seal or the piston seal. I'm sure the O-ring could be serviced, but that involves cracking the case seal, which will then probably leak. I had one die several years after I opened it to repair a faulty gear—it spun on the shaft—I didn’t get the sealing O-ring into perfect position and it was pinched, just a bit, in one spot.

To continue reading this article or issue you must be a paid member.
JOIN NOW

Join Practical Sailor

Get full access to Practical-Sailor.com – more than 4,000 articles – for just $34.
Join today and save 42% off our full price.
Already a member?
| Forgot your password? | Activate Web Access
Drew Frye
Drew Frye, Practical Sailor’s technical editor, has used his background in chemistry and engineering to help guide Practical Sailor toward some of the most important topics covered during the past 10 years. His in-depth reporting on everything from anchors to safety tethers to fuel additives have netted multiple awards from Boating Writers International. With more than three decades of experience as a refinery engineer and a sailor, he has a knack for discovering money-saving “home-brew” products or “hacks” that make boating affordable for almost anyone. He has conducted dozens of tests for Practical Sailor and published over 200 articles on sailing equipment. His rigorous testing has prompted the improvement and introduction of several marine products that might not exist without his input. His book “Rigging Modern Anchors” has won wide praise for introducing the use of modern materials and novel techniques to solve an array of anchoring challenges. 

RELATED ARTICLESMORE FROM AUTHOR

2 COMMENTS

  1. I bought the UK cover on EBay and have been happy with it. It must have been redesigned because the bottom is open (so no greenhouse effect). initially I balked at the high price and (with shipping from the UK) partly because the best (light) colors where out of stock. Once the version in white became available I ordered, having experienced the “heat stroke” problem. Now I have a new problem: my ST2000 is making noises and operating more slowly than in the past. I fear some internal gears are wearing or need grease. I’m a little hesitant to crack the case open, but nor do I want my four-year-old pilot to die an early death. Any tips on types of grease to use on the gears?

  2. Cracking the case is not a big deal. There is a thin gasket around the perimeter; be careful to get it back in position just so when closing it back up. A little light grease will help it stay in place and help it seal by repelling water.

    Any waterproof synthetic grease will be fine. Green Grease (yes, that is a brand) and Superlube Synthetic Grease are good choices. Not too much. A very little grease on the piston shaft as well; wipe off all of the excess.

    My pilot is 15 years old. I have opened it and greased it once. It gets regular use, but it is a very light boat.